Montanhydraulik Report No 6

intelligent Power
Montanhydraulik
The Technology Magazine
In Focus:
Joining the offshore
market together with
Muns Techniek
Nr. 6
In Action:
Installing a hydraulic
system in a dam
In Profile:
Simply colossal –
Bucyrus RH400
In Focus:
Unique lifting vessel
for a wind energy farm
From the world of
manufacture:
Largest single order in
the company’s history
News:
Classical music in the
assembly hall
www.montanhydraulik.com
intelligent Power
editorial
Contents
content
iN Action
Start of operations of a hydraulic system in Vietnam –
The art of “planned improvisation”
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
4
in Profile
RH400 by Bucyrus – The world’s largest excavator
works with cylinders from Montanhydraulik
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Dear Reader,
in Action
The global population explosion and the scarcity of fossil raw materials have led to
Time-critical repair of a multi-purpose press –
Repair of 2,500 tons of push force
an increase in the search and research for alternatives. By now, technology has advanced to such an extent that our oceans and coastal regions, too, have seen intensive utilisation over the past few years in order to replace raw materials such as oil
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
6
8
and gas with renewable energies generated from the powers of wind and water.
in Focus
The technological requirements connected with this are enormous. Due to an ever
Montanhydraulik engages in strategic cooperation with Muns
12
Techniek – Full steam ahead into the offshore market
– –––––––––––––––––––––––––––––––––––––––––––––––
increasing demand totally new concepts, suitable specialist equipment, and ever more
powerful ship types for the erection of maritime platforms and power plants have to
be developed that can withstand the extraordinary conditions experienced offshore.
We have been able to expand our know-how in this market segment significantly,
primarily by way of a strategic cooperation between Montanhydraulik with the Dutch
In Focus
RWE Innogy invests in wind power – Gigantic construction
14
ship for the construction of wind farms
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
company Muns Techniek. The system technology of our Dutch partner, coupled with
From the world of manufacture
the special cylinders tailored for offshore application, is now used by renowned
Successful increase of productivity and quality –
Harry à Wengen right on track
18
Largest ever single order in the history of Glückauf –
From Gelsenkirchen to the Arctic Circle
19
companies: The jack-up rig “Thor” from Hochtief Solutions AG began its first largescale operation last year in the North Sea. Two of the largest construction ships ever
to have been ordered are currently being built in a Korean shipyard for RWE Innogy
and will be put in operation in the course of 2011. And just in: an order from the
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Sietas Shipyard in Hamburg for the hydraulic jack-up system of a construction ship
for the Dutch company Van Oord.
News
For the next few years we have set ourselves the target of systematically expanding
International congress “Hydro 2010” in Lisbon –
On the road in all matters of hydro dams
20
Industrial trade show in France –
Many potential customers at SEPEM
21
the application area Offshore. This means hydro-mechanical engineering, an area
in which we have been increasingly successful in the past, is being complemented
sensibly. But we are also aiming at strengthening our position with a high degree of
innovation and technical competence and want to expand our international standing
in conventional application areas such as mobile crane construction, large excavators and tunnelling machines.
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
– –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Montanhydraulik hosts classical concert –
Cello sounds ring out from the assembly hall
––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
22
Internal News
Personnel development
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
23
Dr. Peter Lipphardt
A
3
in action: Start of operations of a hydraulic system in Vietnam
intelligent Power
Start of operations of a hydraulic system in Vietnam
Individual steps in the installation and start
of operations of the hydraulic system
The art of “planned
improvisation”
• Connecting the power and control cables to the switch cabinet
•Filling the aggregate with oil and filtration
•Pressure testing of pipe work
•Moving of the cylinder
• Bolting of inlet valve with the cylinder head
•Lifting of the two 200 ton piston valves
In issue No. 4 we reported on the construction of the largest dam in Southeast Asia – the Son La dam – planned to supply Vietnam’s
capital Hanoi and the northern Delta region with water and electricity from 2013. Large-scale projects of this kind always necessitate
•Regular consultation with site supervision and the foreman
from steel construction
long-term planning. Alone for the development, production and testing of the hydraulic system the engineers at Montanhydraulik
•Induction and training of operating staff and operator
required a whole year, before the system could finally be shipped to Vietnam in the summer of 2010, where it was then transported on
•Driving the cylinder into the final internal position after successful
sealing of the maintenance valve
land for another 320 km until reaching its destination.
•Draining of oil from the buffer tank
•Opening of the cylinder floor
At present these systems, consisting of twelve hydraulic cylinders
For the installation of the hydraulic systems at the Son La dam the
weighing 38 tons each, the hydraulic aggregates and control units,
engineers from Montanhydraulik had to adjust, amongst other things,
are being assembled, installed and put into service. A process that is
the conduit for the piping and cabling, as well as the measuring poin-
not possible without incidents and where improvisation is therefore
ter in terms of scale length and limit switch positioning, to suit local
already a ‘planned fixture’.
conditions. When it then also became apparent that a check valve
•Installation of mechanical measuring pointer
had to be dismantled and reassembled the team was confronted by
•Calibration of mechanical displacement measuring system
In the case of the Son La dam, both geographical and technical factors
the problem of not having a suitable wrench at hand. “We solved
• Setting the cylinder speed at the 2-way directional valves
complicate progress. The infrastructure is, for example, rather limited
the problem by welding together a 60 mm wrench from bits of steel”,
• Setting the limit switches for the redundant position control
due to the site being a remote location in the mountains. Hence, ad-
reports Roland Skupch. “Professional improvisation is part of our
justments frequently have to be made with tools and materials that
everyday working life.”
•Mounting of wire rope sensors for the electrical and mechanical
displacement measurement
•Calibration of electrical displacement measuring system
•Commissioning and start-up of operations of the first unit’s
hydraulic system
were taken to site from Germany. Other complications are the high exposure to dust and the danger of condensation water forming because
Thanks to the thorough planning and the expertise of the engineers
of the high humidity – a real challenge for the hydraulics.
from Montanhydraulik and that of local partners the installation and
start of operation of the hydraulic systems were accomplished, although
International coordination
with slight delay, but safe in the knowledge that the team had contributed to the safety and proper functioning of this modern dam.
Michael Hillen and Roland Skupch from Holzwickede were present
on site for the installation and the start of operation of the first unit
The first turbine is already producing electricity. The largest dam in Southeast Asia is to be completed by 2013.
of this hydraulic system. Together with several engineers from Montanhydraulik India they coordinated the installation of the cylinders. They
maintained close cooperation with contacts from a diverse range of
nationalities, from installation contractors and operators, the Vietnamese site supervision to an engineering consultant from Japan, and
last but not least, the Thai representative of Liebherr, who was in
charge of the concrete mixing plant.
“It is an exciting task to realise a project of this size together with colleagues and partners under unfamiliar climatic conditions. Every part
section has to be perfectly matched to the next, only then can the entire system function as one”, explains Michael Hillen. “The production of
the hydraulic system in Germany forms the basis – it then starts getting
really interesting in the end phase, when the final adjustments have to
be made.”
Engineers of widely different nationalities discuss the common approach.
The electrical control for the aggregates is housed in six switch cabinets.
Positioning of the cylinder.
Six hydraulic aggregates were shipped in containers to Vietnam.
A
5
in Profile: Giant Excavator Bucyrus RH400
intelligent Power
RH400 from Bucyrus
The world’s largest excavator works with cylinders from Montanhydraulik
The hydraulic excavator RH400 from Bucyrus HEX GmbH, Dortmund (Germany), is with an overall height of 10 m, a width of 9 m and
the same category as cable dredgers. However, the excavator has
The boom cylinders with a stroke of 3,230 mm and a compressive
a total length of 19 m the largest hydraulic excavator in the world. Since it was first presented to the public in 1997, eleven of these
farther-reaching practical characteristics: If it is fitted with a diesel
force of 590 tons were made by Montanhydraulik, as were the arm and
almost 1,000 ton weighing giants have been made and delivered and are being used in the most diverse regions on earth – from the
engine, it works autonomously and independent of external energy
dump cylinders. The whole hydraulic system is monitored by a PMS
extreme cold in Alaska to the hottest deserts in Australia.
such as electricity. What’s more, the machine can change its location
software and control modules developed by Bucyrus which prompt
without problem, making both fast speeds and the overcoming of
the respective working motions.
steep slopes, climbs and of different levels, possible.
The success story of the RH400 began in the oil sands of Canada’s
tomers. Other excavators have been delivered to Australia to mine iron
north. There, in extreme temperatures averaging –20 ºC, rock-hard fro-
ore and to South Africa for use in a platinum mine.
So as to be able to get the 1,000 ton steel colossus – including its
The RH400 is able to adjust to different geological conditions not only
mechanical, electrical and hydraulic equipment – running at the site
with regard to its mobility. By way of the hydraulically enabled flexible
of operation, its construction is modular. The delivery ex factory consti-
The advantages of the RH400 excavator – extremely high performance
Under defined test conditions the RH400 achieves a maximal produc-
working motions the excavator can realise equal shovel volumes at
tutes a logistic master stroke each and every time. The individual
and reliability – have also attracted the attention of other potential cus-
tion output of 9,000 tons/hour. This brings the hydraulic excavator into
both flat and high walls. Thanks to its TriPower kinematics the RH400
modules are completely pre-assembled in Dortmund and are later
can penetrate walls at any height desired. A single scoop of the 52 m³
put together. The screws alone weigh in at 1,500 kg. To transport
volume shovel transports 100 tons of rock for instance. The shovel
the undercarriage with a weight of 84.2 tons and the boom weighing
size is thus exactly matched to the payload capacity of a heavy duty
89.5 tons overland requires around 25 low-loaders. No less impres-
zen rock surface layers and the actual oil sands are being strip-mined.
vehicle. Only when a skip is filled nearing 100 percent capacity with
sive is the transport of the engine module with its enormous dimensi-
an even number of loadings is capacity utilisation of the equipment
ons of 7,600 x 4,600 x 3,900 mm. Once all modules and components
achieved. In ultra large mining trucks with 400 tons payload capacity,
are onsite, assembly can begin – for which approximately two weeks
it achieves a maximum 4-pass load. If shovels are only half filled, its
must be allowed.
performance is not economical.
The RH400’s impressive performance is achieved by way of an extremely strong propulsion concept. Two high-performance diesel engines
with 16 cylinders each, a displacement of 60 l each and a total performance of both engines combined of 4,500 hp propel the excavator
Technical data RH400
and ensure the fast cycle times required and the enormous crushing
and tearing force of the shovel. As an alternative means of propulsion
there is the option of two electric motors with a total output of 3,200 kW
•Operating weight:
980 t
at an operating voltage of 6.6 kV.
•Engine output:
3,360 kW
•Shovel payload:
90 t
•Shovel payload capacity:
52 m3
90 tons payloads moved by way of
hydraulics
This enormous force is used exclusively to propel an extremely powerful hydraulic system that enables all working motions of the hydraulic
excavator. Fed from a 10,000 l capacity hydraulic oil tank eight main
With 4,500 hp the RH400 has as much power as 100 small cars.
pumps press up to 7,500 l/min through cylinders and engines.
Technical data cylinders:
•Boom cylinders:
480/300 x 3,230 mm,
max. compressive force 590 t
•Stick cylinders:
370/250 x 2,900/2,750 mm,
max. compressive force 350 t
•Dump cylinders:
300/180 x 300 mm
A
7
intelligent Power
in action: Cylinder repair of a multi-purpose press
Time-critical repair of a multi-purpose press
Repair of 2,500 Tons of
Push Force
Steel and rolling mills supply their customers, for example power plants, with building components made from heavy plates that they
cannot manufacture themselves. In this category fall machine-worked pieces, spherical segments and single or multi-part container
bases and pressed parts. The latter are reshaped with the aid of multi-purpose presses or so-called hydraulic floor presses.
A multi-purpose press at the Dillinger Hütte with a total push force
Since repair works could not take longer than two weeks, Dillinger
of 2,500 tons had seen its last overhaul in the 1990s; so over recent
Hütte awarded the contract to Montanhydraulik Reparatur und
months wear-and-tear started to increase. After an impressive run-
Service from Dortmund, Germany, who have the technical know-
time of more than 20 years in multiple shift operation the piston rods
how for cylinders of this size and the manufacturing technology to
finally showed the strain with heavy scoring, while the seals were
deal with such weights and dimensions.
clearly worn out.
A
9
in action: Cylinder repair of a multi-purpose press
intelligent Power
After dismantling of the central plunger cylinder, Montanhydraulik Repa-
Once the hydraulic pressure testing had been completed, the base cover
ratur und Service first planned the extensive modification of the piston
had to be unscrewed again to be loaded for shipping separately. Only
seal into a more modern piston seal system from Merkel-Freudenberg,
this way was it possible to re-assemble the central plunger cylinder
a company that specialises in heavy duty seals. In this case, a slide
back into the multi-purpose press passing it through the factory roof
seal system with hard tissue guiding bands. The guides for the moving
of the Dillinger Hütte.
cylinder pipe made of bronze with an outer diameter of 1,250 mm also
had to be completely renewed and had to be adjusted to fit the newly
Finally, all assembly works could be achieved within the allocated time
cut outer diameter of the central ram to ensure an exactly aligned and
frame: The central plunger cylinder was loaded onto a low-loader through
jerk-free operation of the press ram.
the factory roof and left the factory halls of Montanhydraulik Reparatur
und Service GmbH together with the other overhauled cylinders in good
Technicians from Montanhydraulik Reparatur und Service screw-in the cover to the cylinder.
Just two weeks for 13 cylinders
Tightly packaged and secured the 36 ton cylinder is delivered from Dortmund to the
Dillinger Hütte using a low-loader.
time for Dillingen.
In addition to the central plunger cylinder the eight hold-down cylinders
and plate holder cylinders, as well as the four clamping cylinders were
Technical data
ordered to be overhauled. In total this meant overhauling 13 cylinders,
including the central plunger cylinder with a stroke of 3,500 mm and a
weight of 36 tons in just two weeks. “The particular logistic and technical challenge lay in having to precision cut and grind the piston rod
Central plunger cylinder:
of the central plunger cylinder within the available time span, and to
•Piston diameter:
870 mm
harden and finish it”, reports Heinz-Peter Kupiek, Managing Director
•Rod diameter:
710 mm
at Montanhydraulik Reparatur und Service. Here, primarily the precise
•Stroke:
3,500 mm
coordination with the hardening and grinding shop was important.
In the next step the piston rod is lifted through the factory ceiling and is assembled into the vertically ...
However, repairs of such complexity always hold one or two surprise
tasks in reserve. And this case was no exception: In order to be able
to fit the piston rod into the cylinder barrel and to perform the hydrau-
•Leading outer diameter
of the cylinder barrel:
1,200 mm
•Weight:
approx. 36 t
•Operating pressure:
250 bar
lic pressure and function testing, a special retaining jig had to be
12 further hydraulic cylinders:
designed and erected first, fastened to two pillars of the factory hall,
•4 clamping cylinders, plunger diameter 320 mm
because both assembly and the testing of the cylinder could only be
carried out in a vertical position. At the same time it had to be ensured
At the other end in Dillingen, another crane again lifts the cylinder through the opened factory ceiling.
•8 hold-down and plate holder cylinders
with a rod diameter of 250 mm
that the cylinder would not topple.
The retaining jig held the heavy cylinder colossus without problem, but
it turned out that the assembly of the 6 ton cylinder cover would end
up causing the greatest problems.
Performance by Montanhydraulik Reparatur und Service:
•Cutting/machining and hardening of the central plunger cylinder´s
piston rod
•Coating of the clamping cylinder with SuperCoat
Precision work hour for hour
... positioned cylinder barrel.
•Hard-chrome plating of the piston rods for the plate holder and
hold-down cylinders
•Honing of all cylinder barrels
After that the testing of the cylinder is carried out.
The technicians needed two whole night shifts to screw the base
cover to the cylinder with the assistance of a rotary disk that could
be adjusted in height and angle position. The screws of the base
cover were fastened to the cylinder barrel requiring three workers to
inch forward, millimetre by millimetre. Only the smallest angle deviations in the alignment between pipe and cover thread could block the
screwing-in process and could cause great delays. In this process
the cylinder barrel was hanging off the hook of a truck crane, which
had been lowered through the opened factory ceiling and which was
remote-controlled by radio.
Technicians at Dillinger Hütte receive the cylinder on the multi-purpose press.
•Renewal of all bronze guide bushings
•Replacing seals for rods and pistons
•Modification of piston guiding and piston seals to a slide seal
system from Merkel
•Machining of the leading outer diameter of the central plunger
cylinder`s barrel
•Producing new guide bushings with a diameter of 1,250 mm, adjusted
to the cut and machined outer diameter of the central plunger cylinder
•Vertical assembly and hydraulic pressure and function testing
in a purpose-made retaining jig
•Returning the central plunger cylinder with special transportation
requiring special authorisation
Following the dismantling of the base cover the cylinder is again lifted and removed through the ceiling.
The new cylinder is expertly inserted and assembled with ultimate precision.
11
A
intelligent Power
in focus: Strategic cooperation with Muns Techniek
Montanhydraulik in strategic cooperation with Muns Techniek
Full steam ahead into
the offshore market
The management of both companies at the signing of the contract.
The latest trend in the offshore sector: the construction of wind farms.
Almost 18 percent of electric energy produced in the world today is generated by hydroelectric power plants. Following the steady
expansion of this potential for more than two decades, the consistent utilisation of wind energy is now gaining in importance.
The driving forces behind the expansion of wind power generation have been Germany and the EU. Germany alone is planning the
installation of offshore wind farms generating a capacity of around 25,000 MW by 2030. So as to achieve this objective, harbour infrastructures and specialist ships and loading facilities must be developed and produced. Numerous industrial sectors will benefit
from new orders in the wake of this. The offshore industry is thus becoming an important foundation for the maritime sector.
Montanhydraulik also recognises the extremely good develop-
Muns Techniek delivered the corresponding hydraulic power units
ment potential of the renewable energies market. As a hydraulics
and electrical control systems. The good cooperation formed a vital
specialist, whose solutions have been successfully applied for
prerequisite for both companies being awarded the contract to joint-
several decades especially in mobile and harbour cranes, and in
ly supply the hydraulic lifting system for two of the world’s largest
hydro-mechanical engineering, Montanhydraulik has by now also
construction ships that are currently being built for RWE Innogy GmbH.
established itself as a very successful system supplier of a diverse
range of hydro-mechanical configurations for the offshore market.
Initially, the cooperation was based on a handshake agreement bet-
The performance spectrum ranges from engineering to supplying
ween the two chief negotiators, John Jacobs and Dr. Peter Lipphardt.
hydraulic cylinders, machinery aggregates, software and control
In March 2011 the handshake agreement was officially sealed with
systems right down to installation and operation start-up.
a strategic cooperation contract between Montanhydraulik and the
Dutch company.
Competent partnership
“We work extraordinarily well together, complement each other
and thus complete our respective professional competences”,
An important step towards the offshore segment was made by Mon-
says Dr. Peter Lipphardt, Chairman and Managing Director of
tanhydraulik entering into a strategic cooperation with the Dutch
Montanhydraulik.
company Muns Techniek B.V. The internationally operating company
specialises in the development and manufacture of hydraulic instal-
The latest success story of this cooperation is the order received
lations and controls, amongst others in the sectors of wet dredge
from J.J. Sietas Werft, a Hamburg shipyard, for the supply of a com-
mining and general ship construction. In past years Muns Techniek
plete lifting system for the offshore ship of the company Van Oord,
impressed primarily with outstanding solutions for offshore applica-
which has been commissioned by a Dutch shipping agent.
tions such as jack-up platforms and construction ships.
Montanhydraulik and Muns Techniek intend to expand the Dutch loIt was during the realisation of the jack-up rig “Thor” for HOCHTIEF
cation Sleeuwijk, starting as early as this year. The increase in capa-
Solutions AG that Montanhydraulik and Muns Techniek met for the
city thus created forms the ideal basis for the realisation of further
first time. Montanhydraulik supplied the 50 pull cylinders, while
large-scale projects in the offshore sector, and in other sectors as well.
13
A
intelligent Power
in focus: Construction ships for offshore wind farms
RWE Innogy invests in wind energy
Gigantic construc tion ship for
the construction of wind farms
15
A
intelligent Power
in focus: Construction ships for offshore wind farms
The demand for wind power has lately risen so dramatically that
Technical data construction ship
operators of offshore wind farms can hardly keep up with the
construction of these large wind power stations. The main reasons for this are the difficult installation at high seas and the loading capacity of transport ships, which until now has been limited.
So as to avoid supply bottlenecks for their own projects, RWE
•Classification:
GL, 100 A5 self-elevating unit DP2,
MC-AUT
Innogy GmbH has commissioned construction of two offshore
•Total weight (without legs):
specialist ships of the same type with the Korean shipbuilder
Main dimensions:
Daewoo Shipbuilding & Marine Engineering.
15,602 t
•Length:
109 m
•Width:
40 m
After their completion the construction ships, 109 m long and 40 m
•Leg length:
78 m
wide, will be able to not only transport up to four offshore wind tur-
Application area:
bines of megawatt class 5 and 6 complete with foundations and even
under rough sea conditions, but will also be able to erect them. This
gives the company significant time and cost advantages.
Novel control for lifting system
Montanhydraulik and Muns Techniek jointly supply the complete
hydraulic lifting system for the ships, consisting of cylinders, bolting
units and guide frames, and the corresponding hydraulic power unit
•Max. loading weight:
4,200 t (= up to 4 x 5 megawatt turbines)
•DP2 positioning (satellite-controlled)
•Water depth:
more than 40 m
•Speed:
up to 7.5 kn
Core components/features:
•Max. hook height main crane: 110 m above deck
•Max. load capacity main crane:1,000 t up to 21 m; 800 t up to 25 m;
500 t up to 38 m
•Propulsion force:
6 pivotable thrusters: 6 x 1,600 kW
of the ships lies in two, per supporting leg synchronously movable
•Accommodation aboard:
max. 60 people, mainly single cabins
lifting frames, whose movement is controlled by a synchronous con-
•Helicopter platform:
diameter 17 m
and electrical control system. The particularity in the construction
trol system especially developed for this project. Because of this it is
possible to implement the lifting and lowering of the four supporting
legs via the required stroke in synch, without the need for stopping
the platform for the bolting procedure.
The ships, whose order value lies at around 100 million Euros each,
can be fixed into position to the exact centimetre in the sea via satellite. They are capable of operating in water depth of over 40 m and
are thus ideally suited for constructing the offshore wind farms planned by RWE Innogy.
Sailing from the base port Bremerhaven the first construction ship will
initially set the foundations for the wind farm project “North Sea East”
with an output of 295 MW. It will subsequently transport and install
a total of 48 wind turbines of megawatt class 6 to the destination.
The wind farm is planned to be completed by 2013 and is expected
Technical data hydraulics:
•Hydraulic performance:
3,990 kW
•Max. oil flow:
9,600 l/min
•Max. operational pressure:
325 bar
Technical data cylinders:
•48 traction cylinders:
630/280 x 3,000 mm
•Max. cylinder speed,
leg up/down, floating:
1.0 m/min
•Max. effective speed,
leg up/down, floating:
0.84 m/min
•Max. effective speed,
barge up/down:
0.70 m/min
•Piston rod coating:
ceramic with integrated displacement
measurement system
to supply 295,000 German households with electricity.
In addition to the wind farm “North Sea East” RWE Innogy is planning
two further wind farms: “Innogy Nordsee 1” (960 MW) – 40 km north of
the German North Sea island Juist covering an area of 150 km2 – and
the wind power plant “Gwynt y Môr” (576 MW) off the coast of Wales.
17
A
intelligent Power
From the world of manufacture: harry à wengen
The training workshop has all the machinery and tools vital for training up young people for their professional life.
From the world of manufacture: glückauf
After production completion in June, the shields, weighing more than 18 tons, are going to be delivered to Vorkuta in northern Russia, where they will be used in coal mining.
Successful increase of productivity and quality
Largest ever single order in the history of Glückauf
Harry à Wengen right
on track
From Gelsenkirchen
to the Arctic Circle
Viewing a crisis as an opportunity – this in the past possibly over-
Vorkuta, a Russian town 120 km north of the Arctic Circle, is
Moscow and Kemerovo (Siberia). “The reward for all this hard work is
inextricably linked with memories of forced labour camps, the
the largest single order in our company’s history”, rejoices Ulrich Wilde,
notorious Russian Gulags, and indescribable conditions for the
Managing Director of Maschinenfabrik Glückauf.
used phrase nonetheless aptly describes the development at
Montanhydraulik’s subsidiary, Harry à Wengen. The company, spe-
Measures implemented to increase
productivity and quality
inmates working in coal mines and on the construction of the
cialising in the production of cylinders and hydraulic components,
has indeed used the time of economic downturn to improve internal workflows, to reduce the error ratio by 50 percent, and increase
machinery assets. The flip side: Due to the bad economy and bad
results at the end of 2009 Harry à Wengen was forced to pass a
redundancy programme and had to lay off 24 members of staff.
However, all these measures have led to the company from Neubulach,
Germany, to be now in a healthier position in terms of organisation,
•Relocation of machinery between the two plants Talmühle and
Oberhaugstett to streamline production processes
railroad. Coal mining exists to this day, but under a different
The order comprises the repair and modernisation of 200 used roof
name and under modern conditions. For Maschinenfabrik
support extension units from Ruhrkohle AG and the manufacture of
• Acquisition of a grinder and submerged arc welding (SAW) machine
and of two deep boring machines to shorten production times and
to improve quality
Glückauf this is great news.
a new belt crossing, as well as two new track shields. To be able to
• Improving machinery maintenance as well as machine and manual
parts-cleaning in order to shorten downtimes
For three years the mining specialist has been closely cooperating with
•Testing out new tools and manufacturing techniques to shorten the
processing times of components
assisted here by DAT Bergbautechnik, based in Wesel, its sales partner
repair the shields, all legs and cylinders also have to be replaced with
newly manufactured ones.
the Russian coal mining company Vorkuta Ugol. The company is being
Additional assembly hall leased
for Russia and some former CIS states.
manufacture and quality than ever before. In 2010, for the first time in
•Targeted training in manufacturing techniques
six years, the company finally generated a profit again.
•Optimisation of assembly processes through new devices, and
through improved lifting and mounting tools
A belt crossing, special roof support extensions and hydraulic cylin-
“The transport-ready shield alone, weighs in excess of 18 tons and is
ders – the list of items supplied to the mines of Vorkuta Ugol is exten-
made up of more than 100 individual pieces.” To store individual com-
•New organisation of warehouse and logistics area to guarantee
optimal material flow from receipt of goods to dispatch
sive. Glückauf’s most recent delivery to the coal mine Severnaja at the
ponents, assemble the prototype and for the final assembly a further,
end of February 2011 was a double track carriage.
approximately 2,100 m2 large plant section has recently been at hand
This result is good news for its employees, and makes especially the
ten apprentices happy, since it increases the likelihood of being taken
on after completion of their training. For these trainees, who account
for twelve percent of the workforce – and who are therefore an above-
• Improvement of quality through comprehensive controls,
documentations, error analyses, and development tests
“We are dealing with an incredible order dimension”, says Ulrich Wilde.
in the immediate neighbourhood, which was leased to provide additioAlso this February, DAT was able to conclude a contract for the delive-
average segment of it – purposeful investments have been made. In
ry of a complete roof support system and a whole range of other com-
the newly-built training workshop, which is equipped with all necessary
ponents for coal mining operations.
machinery to train machining, drilling, sanding and polishing for in-
nal space for a further large order from RAG Anthrazit Ibbenbüren.
The collection of second-hand shields from the Ruhrkohle colliery
Rossenray in Kamp Lintfort commenced in the last week of February.
stance, the young men and women obtain comprehensive and consis-
A six months negotiating phase preceded this agreement, in which em-
Now all involved are working hard to meet the order deadline produ-
tent vocational training that qualifies them for their professional life.
ployees from DAT and Glückauf worked out the final details in Vorkuta,
cing flawless quality by the end of June.
19
A
news: hydro 2010
intelligent Power
news: Industrial Trade Show sepem
International congress “Hydro 2010” in Lisbon
Industrial Trade Show in France
On the road in all
matters of hydro dams
Many potential
customers at SEPEM
The first trade fair attendance at the French industrial trade show SEPEM in 2010 has already resulted in numerous promising
customer contacts and order enquiries. It was then only logical for Montanhydraulik Reparatur und Service to decide to attend
again this year, and present its service spectrum around the repair of hydraulic cylinders and systems, this time in Douai in the
north of France. The result: 60 contacts in just three days.
Around 400 exhibitors attended the trade
overhauls due to systems becoming outda-
from an aluminium processor from Biesheim,
show from the 25 to the 27 January 2011,
ted, or wear-and-tear and leakages, and only
in Alsace, for overhauling a pouring cylinder.
(which is held in four alternating French lo-
very few repair companies are able to tackle
An industry giant from the steel sector also
cations) presenting products and solutions
cylinders irrespective of their size or can offer
showed serious interest in cylinder repairs of
from all areas of industrial production – from
solutions from a single source.
large scale.
Accordingly, Heinz-Peter Kupiek, Managing
“For us it was the right step to take for en-
th
th
pharmaceutical companies to automotive and
electrical companies, from textile to steel.
Director of the repair company from Dort-
tering the French market”, concludes Heinz-
For relevant large production segments the
mund, also received enquiries from a diverse
Peter Kupiek. “Following the positive feed-
Renewable energies such as hydropower and wind energy have increasingly moved into the centre of energy production and are
portfolio of Montanhydraulik Reparatur und
range of companies, for instance from a well-
back received so far we are going to further
long-term to replace fossil energies. Montanhydraulik had the foresight to adjust to these changes some time ago and is by now
Service proved to be of great interest. This is
known timber and chipboard manufacturer
strengthen our commitment in this region.”
already supplying hydraulic cylinders and systems, which are used in power plants and in dams.
because machinery has to undergo regular
for the repair of a ContiRoll press cylinder, or
At the international congress “Hydro 2010” in
of Montanhydraulik hopes that an expansion
from five different nations. Especially the
Lisbon, Montanhydraulik used the opportunity
of the global sales network will significantly
combined know-how of engineers from
to introduce its latest projects and innova-
help to increase expansion in this already
Montanhydraulik India and their German
tions in hydraulic engineering and to attract
heavily growing market segment.
counterparts was met with keen interest.
partners for cooperation.
The joint competence is reflected for instance
The broad performance spectrum of Montan-
in the computer-controlled flow regulation
“Our aim was to alert sector experts to the
hydraulik, which was presented in an inter-
system ARMAC, which by now is being used
depth of services of Montanhydraulik and
active company presentation as part of an
successfully in several dam projects.
to intensify international contacts”, informs
evening event, received positive feedback
Dr. Peter Lipphardt. The Managing Director
throughout from the special guests coming
At the Montanhydraulik stand ...
... and during the evening event ...
... it’s all about hydro-mechanical engineering.
The repair services were met with great interest from trade show visitors.
Heinz-Peter Kupiek in discussion with sales partner Jean-Pierre Mondoloni.
21
news: Cello Autumn
intelligent Power
news: Cello Autumn | intern: Personnel Development
High-art against an industrial backdrop
By now the Managing Director, who plays the piano himself, has also
Hans Werner Henze and Edward Elgar, Mr. Günther and his team had
infected his staff with his enthusiasm. “We find it quite exciting that
to master a logistics challenge of another kind. The assembly hall was
our hall, where otherwise only hard work takes place, can be transfor-
shut down for three days. Cylinders were removed from the hall, stage
med to host such a cultural event”, says Bernd Günther, Head of New
and seating had to be set up and the catering had to be organised – to
Construction and Maintenance at Montanhydraulik.
the delight of the audience, who continue to have fond memories of
this special evening.
So as to stage the perfect cello concert, which was dedicated to the
composer Robert Schumann, in addition to renditions of Gideon Klein,
The clever use of material and light creates a festive atmosphere.
Selected exhibits from production make reference to the hall’s actual use.
Prof. Alexander Hülshoff from the Folkwang University of Arts tests out the acoustics in the assembly hall: “The sound was carried all the way to the ceiling, where it continued to resonate.”
We welcome the new employee at Montanhydraulik Holzwickede
Montanhydraulik hosts classical concert
Cello sounds ring out from
the assembly hall
Yarkin Cilek
Starting his employment in March 2011, graduate engineer Yarkin Cilek has since been working
in the quality department at Montanhydraulik, where as welding engineer he is responsible for the
coordination of all welding technical activities that need to be carried out for the entire corporate
From the assembly hall 7 one can usually hear the sound of ma-
performed by the Folkwang ensemble on the premises of the cylinder
chinery and the voices of fitters and technicians. This all changed
manufacturer was a particular highlight for the many guests. After all,
on October 21st, 2010: Cello music filled the 4,000 m2 hall, which
the opportunity to experience a production hall and its extraordinary
had been converted into a concert hall with plenty of atmosphere.
acoustics doesn’t present itself too often.
group. After graduating as a civil engineer in 2005 the 34-year-old gained professional experience as
a welding engineer in different companies. Besides his career progression Yarkin Cilek spends most
of his spare time with his wife and child.
Long rolls of fabric framed the scene; individual components and
cylinders were rearranged and lit up with subtle lighting – industry
Prof. Alexander Hülshoff was also astounded, when he put his bow to
and culture in perfect harmony.
the strings of his 320-year-old cello to test out the sound: “The sound
was carried all the way to the ceiling, where it continued to resonate.”
The regional music festival “Celloherbst am Hellweg” (Cello Autumn at
Montanhydraulik acting as concert host and sponsor for such a festival
the Hellweg) was organised for the fourth time last year. On the occa-
is quite atypical for an industrial corporation, but in this case can be
sion of the Capital of Culture Year the arrangement of artists and loca-
explained by Dr. Peter Lipphardt’s love for music.
tions was even more diverse than on previous occasions. The concert
Impressum
Montanhydraulik REPORT | Concept, Editorial Content and Layout: team:penta GmbH & Co. KG, Dortmund, Germany
Images: Montanhydraulik Group, Hochtief, RWE, Bucyrus, Even Pro, Henryk Brock, Westfälische Rundschau, team:penta
Publication date: April 2011 | Print: Scholz-Druck und Medienservice GmbH & Co. KG, Dortmund, Germany | Circulation: 500 copies
23
A
// offshore
15,600 tons are carried with
intelligent Power
0.28 Kilograms
are carried by hand
INTELLIGENT POWER – Today’s world needs intelligent energy generation concepts. One such
example is the construction of wind farms near coastal areas. This requires complex technologies and facilities that are capable of handling such difficult assignments at high seas in the first
place. Jack-up platforms that lift gigantic loads and which, to be able to do so require stable
anchoring in water depths of up to 50 m, are used for the construction of such wind power
stations. The requirements on the hydraulics of such jack-up rigs are extremely high. The wellfounded know-how gained in mobile crane construction and the global experiences gained
in hydro-mechanical engineering make Montanhydraulik one of the most competent partners
in the market today. Together with the Dutch subsidiary Muns Techniek B.V. we develop and
manufacture complete hydraulic solutions from hydraulic aggregates to control systems and
software right down to corrosion-resistant hydraulic cylinders – and all from one single source.
For more information visit www.montanhydraulik.com
Muns Techniek BV
Montanhydraulik Group
Montanhydraulik Group